Petrochemical Plants Research Articles

Development of major process accident indicators based on Industrial Internet

In recent years, Chinese-produced bulk chemical products have consistently ranked among the world’s leading suppliers. The scale of individual petrochemical plants and chemical parks has grown significantly, resulting in increased complexity that can contribute to higher levels of uncertainty surrounding potential losses. MA (major accident) indicators can provide a comprehensive assessment of a plant’s safety performance. This study focuses on three primary objectives: Firstly, utilizing process safety management software powered by Industrial Internet technology, we develop MA indicators. Secondly, applying the Systems-Theoretic Accident Model and Processes (STAMP) theory, this work analyzes the logical relationship between MA indicators and accidents. STAMP provides a more comprehensive understanding of indicators involving multiple barriers. Lastly, drawing upon a large language model, this paper retrospectively analyzes 212 accident reports to verify the connection between the index and actual accidents. It is noteworthy that the MA indicators adhere to SMART criteria for effective measurement.

Evaluation of the Domino Effect Caused by Pool Fires in a Tank Farm

Major hazard installations (MHIs), such as oil refineries, petrochemical plants, and terminals, use large-capacity storage tanks for storing crude oil and by-products. Pool fire is one of the most common types of storage tank fire incidents. This technical article aims to investigate the domino effect resulting from a pool fire in a tank farm consisting of eight large floating-roof storage tanks, with a focus on four specific tanks. A crude oil storage tank was selected as the primary tank (source tank). Point source and plume solid models were used to estimate the thermal radiation. It has been noted that the thermal radiation from the source tank to the adjacent tank in the same dike exceeds the threshold heat radiation level and might result in a domino effect; however, the thermal radiation from the source tank alone does not reach the threshold level for the tanks in the other dike. Additionally, it was found that the thermal radiation from both the primary and secondary tanks just reaches the threshold level for the farther-away tank in the other dike. The domino effect occurs provided that the firefighting system is not activated and the emergency response team does not intervene within ten minutes.

Self-rating scale in self-directed learning in workplace context: a case study of Thai operational employees in the petrochemical plant industry

PurposeThis study addresses the need for a validated tool to assess self-directed learning (SDL) behaviors among Thai operational employees in the petrochemical industry. Understanding SDL capabilities is essential for effective human resource development, given the complexity of plant operations and the need for continuous skill enhancement.Design/methodology/approachThis research adapts the self-rating scale of self-directed learning (SRSSDL) to the Thai workplace context. The SRSSDL was translated into Thai and adapted for the workplace. Five experts validated the content, and validity and reliability testing was conducted with 50 operational employees from Thai petrochemical plants. Confirmatory factor analysis (CFA) and Cronbach’s alpha were used to assess the instrument’s reliability and validity.FindingsContent validation confirmed that all SRSSDL items had an item-objective congruence (IOC) score above 0.5. CFA results showed a good model fit (comparative fit index [CFI] = 0.99, Tucker–Lewis index [TLI] = 0.98, root mean square error of approximation [RMSEA] = 0.02 and standardized root mean square residual [SRMR] = 0.02). Reliability analysis showed Cronbach’s alpha values from 0.91 to 0.96, indicating excellent internal consistency.Originality/valueThis research is the first study to assess and prove the content validity, construct validity and reliability of the SRSSDL in the context of Thai workplaces, particularly in the petrochemical industry. The SRSSDL is a reliable and valid tool for assessing SDL behaviors among Thai operational employees. It enhances human resource development by identifying SDL capabilities and fostering continuous improvement and SDL.

An operational risk assessment method for petrochemical plants based on deep learning

The petrochemical industry is an important guarantee for the development of people’s lives, and the operational risk assessment method of personnel in the operation of petrochemical enterprises is the most important. Based on a deep learning algorithm, a new method based on the micro-Doppler effect and fuzzy analytic hierarchy process is proposed to evaluate the operational risk of personnel in petrochemical enterprises. The original monitoring image of petrochemical equipment is invoked, and micro-Doppler analysis is performed based on the original image to identify the activity target of the personnel on the job site and generate the activity map of the petrochemical plant operators. Based on the analysis data of the micro-Doppler effect, the fuzzy function and hierarchical analysis method are combined. The fuzzy theory is introduced into the analytic hierarchy process, and the inherent expert evaluation scores are transformed into fuzzy numbers. It makes the expert evaluation of petrochemical plants more accurate in the subsequent coupling and improves the objectivity of the traditional analytic hierarchy process. The scheme proposed in this paper can monitor real-time operation safety and provide a guarantee for the personal safety of field operators. This method plays an important role in improving the safety of petrochemical plants.

Composite Risk Assessment of HNS Discharged from Marine Industrial Facilities: A Case Study on Incheon Port, South Korea

This study conducted a composite risk assessment to evaluate the environmental impacts of phenol, a Hazardous and Noxious Substance (HNS) released or leaked from port facilities. The study area was designated as the vicinity of Incheon Port, South Korea, where the volume of petrochemical-related materials is substantial and various industrial facilities are located. For the composite risk assessment, various vulnerability maps were developed, incorporating the dispersion range of phenol calculated through numerical modeling. The vulnerability maps were generated by classifying socio-environment, legally protected areas, habitats, and species, followed by integrating these individual vulnerability maps to construct an integrated vulnerability map. The composite risk assessment was conducted by considering both the integrated vulnerability map and the dispersion range of phenol. The assessment results indicated that the highest risk by depth was observed in the lower layers due to the settling characteristics of phenol. Spatially, areas where islands and coastlines converge exhibited relatively higher risks. This was attributed to the high concentrations of phenol released from industrial facilities, such as crude oil refineries, petrochemical plants, and organic compound manufacturers, in regions characterized by intense human activity, sensitive habitats, and legally protected areas. Continuous monitoring of these high-risk areas is crucial for assessing the environmental impacts of HNS substances like phenol.

Design and Optimization of a Chemical Looping Hydrogen Production System Using Steam Reforming for Petrochemical Plants.

Industrial pollution is a significant environmental concern, and researchers are seeking solutions to minimize its impact. Chemical looping combustion is an efficient technique to decrease CO2 emissions. This study delves into its application within petrochemical plants for hydrogen production. In addition to its high efficiency in hydrogen production, this method yields pure CO2 and nitrogen. The design features four reactors utilizing iron and nickel metals as oxygen carriers. A model in Aspen Plus was developed to simulate this design and evaluate its performance. Aspen Plus uses RGIBBS submodel which works based on minimization of the Gibbs free energy. The research findings indicate that this design significantly boosted the hydrogen production rate from 3380 kmol/h in conventional steam reforming reactors and 4258 kmol/h in the three-reactor chemical looping combustion setup to 4408 kmol/h. Lowering the temperatures of the iron and nickel fuel reactors, as well as the iron steam reactor, reducing the airflow rate, and increasing the pressure of the iron steam reactor all led to increased hydrogen production. Conversely, changing the pressure of the nickel fuel reactor had minimal impact. The inlet steam flow rate exhibited a nonlinear effect, initially increasing and then decreasing the hydrogen production rate.

Filtering ‘3–2’ industrial symbiosis networks at a carbon-intensive cluster in a small island developing state to reuse CO2 and water

Small island developing states (SIDS) face internal and external pressures for more sustainable manufacturing e.g., economic and ecological water provision, and anti-carbon leakage tariffs. As SIDS have special developmental challenges, locally appropriate strategies are needed. In one of these SIDS, Trinidad and Tobago, is a carbon-intensive industrial cluster of global standing, the Point Lisas Industrial Estate (PLIE). So, to investigate ‘3–2’ industrial symbiosis (IS) on the PLIE, a simple enterprise input-output MILP model of a representative IS network was developed. Different quality wastewater streams and high-purity process CO2 from ammonia processes were selected as materials to be reused in: existing petrochemical plants, a mineral carbonate factory and a propylene carbonate plant. To filter the IS relations, economic and environmental objectives were set for each material. Combining economic objectives left a tri-objective problem, which was resolved with ε-constraint optimization and multi-criteria decision-making methods. Kleinberg's hub and authority scores were found to give beneficial insight into the solved IS networks. Potential revenue-generating opportunities were uncovered for sharing and reusing water and process CO2. The results suggest adding two proposed carbonate factories could increase the mass of CO2 reused in the cluster by 10.4 % and mitigate releasing 5 Tg/y of rejected desalination brine.

Electricity supply resiliency evaluation by a hybrid renewable energy system for a petrochemical plant: Frameworks and quantitative assessment methodologies

The escalation of harm inflicted upon energy systems, has spurred the investigation of energy system resilience. In this regard, the measurement of resilience capacity can serve as a valuable metric for assessing the energy system's ability to withstand a variety of events that may result in potential adverse outcomes. For renewable energy systems, the measurement of resilience is imperative due to the inherent unpredictability and unreliability in their nature. Often, resilience studies lack the comprehensiveness required to fully comprehend the intricate interdependencies within integrated hybrid renewable energy systems. This research delineates the essential factors required to facilitate a comprehensive understanding and advancement in the quantification of such integrated systems in small-scale. Pardis Petrochemical Company, located in Asalouyeh city, Iran, has been chosen as case study. Four distinct configurations of hybrid renewable energy systems—comprising Photovoltaic panels, Photovoltaic panels + Wind Turbines, Photovoltaic panels + Wave energy converters, and Photovoltaic panels + Wind Turbines + Wave energy converters— connected to grid, have been developed. These configurations are the result of a multi-objective optimization process, considering the following metrics: the cost of electricity (as an economic metric), CO2 emissions (as an environmental metric), loss of power supply probability (as a reliability metric), and exergy efficiency (as a technical metric). Subsequently, a methodological framework for multicriteria decision support is introduced. This framework is constructed based on primary resilience dimensions, namely: “resist,” “restabilize,” “technology,” and “withstand” serve as a tool for measuring the resiliency of the optimized configurations. The findings indicate that the Photovoltaic panels + Wind Turbines + Wave Energy Converters configuration is as the most resilient system among the studied alternatives.

Movable VOC Removal System

In this study, we develop a mobile VOCs gas removal system that can remove volatile organic compound (VOCs) emissions from petrochemical facilities, metal painting factories, and surroundings of life, and can efficiently cope with situations occurring in the field. Regular repairs to petrochemical plants and semiconductor plants are carried out for a month every four to five years, and work such as replacing old pipes and repairing aging facilities, cleaning, removing residual gas, checking pipe connections and valves, and improving processes are carried out while the plant is shut down. During regular maintenance, a large-scale accident occurs in which gas remaining in the facility leaks or explodes due to rising pressure, and even after internal gas discharge and purge work is performed, it is scattered by the characteristics of raw materials remaining inside the pipe and reactor and discharged into the atmosphere. Therefore, there is always a possibility of causing safety accidents, and such accidents have a great socioeconomic impact as they are directly connected to the safety of workers as well as the safety of local residents. This system is designed to be adaptable according to the size of a number of outlets, and it is proposed to minimize the impact of VOCs harmful gases on the surroundings by developing it as a mobile type. The efficiency of collecting scattered VOCs gas is more than 90%, and the integrated operating system is demonstrated for 50 CMM class movable VOCs adsorption device, 5 CMM class treatment gas recirculation type non-flame waste heat recovery adsorbent regeneration treatment device, and two or more business sites.

The Why, What, Who, When, and Where of Carbon Capture and Storage in Southern Ontario

This paper reviews the five Ws (Why, What, Who, When, and Where) of carbon capture and storage in southwestern Ontario. This area is home to nearly one quarter of Canada’s population and approximately three-quarters of one million people work in the manufacturing sector. Fifteen of the province’s top 20 CO2 emission point sources are in this area. The industries responsible for these emissions include steel mills, refineries and petrochemical plants, and cement plants. These industries are part of the hard-to-abate sector, in that CO2 is used or generated as an integral part of the industrial process. As such, eliminating or even reducing emissions from these industries is a difficult task. Carbon capture and storage (CCS) projects aim to sequester that gas in sedimentary basins over periods exceeding several thousand years. To this end, deeply buried (> 800 m) porous and permeable rocks (a repository) must be overlain by impermeable rocks that act as a seal, preventing the upward migration of CO2 into the atmosphere. The possibility that injection activities could trigger seismicity is but one of the additional considerations. When operational, CCS projects have a negative carbon footprint and the desirability of developing and using this technology has been established for over 20 years. True CCS projects differ from carbon capture, utilization, and storage (CCUS) projects in that the former are only designed with sequestration in mind. One type of CCUS project involves using CO2 for enhanced oil recovery (EOR) and this technology has been employed for several decades. Cambrian sandstones are the most suitable injection targets for CCS in southwestern Ontario because previous oil and gas drilling has shown the rocks to have the necessary characteristics. They are buried below 800 m, can be tens of metres thick, and have adequate porosity and permeability. However, the Cambrian section is lithologically and stratigraphically heterogeneous and oil, gas, and brine can all be present in the pore space. The extent to which this complexity will affect CO2 injection has not yet been evaluated.

Selection of technological basis for intelligent anti-corrosion coating for protection of oil refining equipment

Subject of research: intelligent coating to protect oil refining equipment from corrosion, its protective and operational properties. Purpose of research: to develop the composition of an intelligent coating to protect oil refining equipment from corrosion, to study its basic operational characteristics, to test protective properties in aggressive environments. Methods and objects of research: samples made of 09G2C steel used for the manufacture of technological equipment of oil refineries and petrochemical plants, coated with various protective compositions to determine the main characteristics of the composition of the intelligent coating. To study the operational properties, a technique has been developed using magnetic stirrers that simulate the repeated interaction of a corrosive medium with samples. Main results of research: according to the results of climatic tests and chemical resistance of coatings in a corrosive environment, the most effective composition of the base of an intelligent coating with the best protective characteristics has been established and its necessary adhesive properties have been determined.

Modelling and experimental study on pipeline defect characterisations using a pulsed eddy current measurement

ABSTRACT Pipelines are widely used as the main transportation method in petrochemical and metallurgical industries. However, the special nature of the materials transported in pipelines means they are often subjected to high temperature, high pressure and corrosive conditions. This can lead to defects, such as thinning and cracking, resulting in pipeline failure and causing serious economic losses. Therefore, regular non-destructive testing of pipelines is particularly important. This paper uses the non-destructive testing method with pulsed eddy current technology to characterise pipeline thinning and defects. A preliminary study is conducted on the pulsed eddy current detection signal patterns for pipeline crack defects with varying orientations and quantities. A more portable pulsed eddy current detection device with an extended wall thickness detection range is developed. It can achieve measurements with a maximum thickness of 30 mm for detections of pipelines with rectangular defects and thickness-stepped reduced. The experimental results are consistent with modelling results, and the accuracy for pipelines with insulation layer is also investigated. On-site measurements using the PEC system are conducted on equipment sections with pipe thickness within 20 mm in a petrochemical plant. It is confirmed that the developed PEC inspection device can accurately characterises the thickness of pipelines with 0–50 mm cladding.

Efficient risk-based inspection framework: Balancing safety and budgetary constraints

Efficient equipment maintenance is paramount across various industries to mitigate energy wastage and avert potential disasters such as hazardous emissions, fires, and explosions. Within this context, the adoption of risk-based inspection strategies has emerged as a crucial method for assessing equipment integrity. This study integrates the principles of Risk-Based Inspection (RBI) with a novel two-objective mathematical model, resulting in a comprehensive framework for equipment inspection programs. The primary aim of this framework is to reduce overall risk exposure while optimizing inspection expenditures. Unlike conventional approaches, this methodology eliminates the necessity to define threshold risk levels. By integrating inspection costs into the model, the assessment of Failure Consequences, and thereby, the decision-making process has been streamlined. This innovative algorithm effectively balances the reduction of failure likelihood with the minimization of inspection costs, enhancing decision-making capabilities. Importantly, this approach offers significant protection against energy wastage and the occurrence of leaks through robust risk management strategies. The algorithm employs specialized operators to expedite the discovery of optimal solutions. Empirical validation through a case study conducted at a Petrochemical Plant highlights the practicality and effectiveness of the proposed framework.

Boron-modified super duplex stainless steels: microstructure, hardness, and industrial applications

In this work was investigated the boron modified super duplex stainless steel processed by spray-forming, to characterize the workpiece using different techniques, among them, optical microscopy, SEM-FEG, X-ray diffraction, Rama spectroscopy and Vickers hardness (VH) and Thermo-Calc software. As result, in this research was verified that in the ferrite phase the Cr element predominates, but in the austenite phase the Fe and Ni elements prevail by the EDS technique. As well as XRD spectra showed different meta-stable phases and (FeCr)2B phase. Besides, the Vickers microhardness measurement was around 460 HV, being much taller than the duplex stainless steel. This alloy can be successfully used in the chemical, oil and gas industries, petrochemical process plants, the pulp and paper industry, pollution control equipment, transportation and for general engineering thanks to their outstanding corrosion resistance and mechanical properties.

ENGINEERING MANAGEMENT PERSPECTIVES ON SAFETY CULTURE IN CHEMICAL AND PETROCHEMICAL PLANTS: A SYSTEMATIC REVIEW

This systematic review examines the influence of engineering management practices on cultivating and sustaining a strong safety culture in chemical and petrochemical plants. Given the high-risk nature of these industries, establishing a robust safety culture is essential for mitigating operational hazards, reducing risks, and preventing accidents that can have serious human and environmental impacts. The review synthesizes findings from 135 peer-reviewed studies, focusing on key elements such as leadership commitment, employee engagement, regulatory compliance, safety management systems, and the integration of advanced technologies like automation and artificial intelligence (AI). The results highlight that safety performance in these industries is closely linked to management's active involvement in promoting safety practices, clear communication strategies, and the continuous assessment and improvement of safety protocols. Engineering managers play a critical role in driving safety initiatives and fostering an organizational culture where safety is a shared responsibility. The review also underscores the importance of regulatory compliance as a foundation for safety, while emphasizing that the most successful organizations go beyond compliance to embed safety deeply into their operational practices. Technological advancements, particularly in automation and real-time monitoring, were found to significantly enhance safety outcomes by enabling proactive risk identification and mitigation. Overall, this review offers valuable insights and practical guidelines for engineering managers aiming to strengthen safety protocols, reduce risks, and enhance safety performance in high-hazard industrial environments.

Острые интоксикации в условиях химических производств и меры профилактики

Occupational diseases caused by the chemical factor, including acute intoxications, continue to be reported in enterprises of the petrochemical industry. In this regard, studying the etiological factor causing acute intoxication, as well as the circumstances and causes of its occurrence among various professional groups of employees is still urgent. A retrospective analysis of materials of the investigation of occupational diseases caused by acute intoxications that occurred within 50 years (from 1967 to 2022) at the largest petrochemical plant located in the Volga Federal District has been conducted. An in-depth analysis of acute occupational disease risk indicators at the plant has shown that for the analyzed period, 124 cases of acute occupational poisonings, both collective and with one victim were reported. The high professional risk of health disorders due to acute poisonings has been detected for employees of the main professions: operators, machinists, and process equipment repair mechanics. The most significant factors causing acute poisonings were ammonia (23.4 % of all cases), hydrogen sulfide (17.3 %), carbon monoxide (10.7 %), and aromatic hydrocarbons (9.8 %). The main areas of chemical factor risk minimization have been developed based on the analysis.

Industrial wastewater treatment from oil and petroleum products with carbonate sludge

In the modern world, pollution of industrial wastewater by oil and petroleum products is one of the most acute environmental problems. These pollutants have a significant negative impact on ecosystems and water quality. In this regard, there is a need to develop effective and environmentally safe methods of wastewater treatment. The aim of the study is to develop and evaluate the efficiency of using carbonate sludge as an adsorbent for removing oil and petroleum products from wastewater. The scientific and practical significance of the work lies in the proposal of an environmentally friendly treatment method that can not only improve the quality of wastewater, but also ensure the disposal of industrial waste. The use of carbonate sludge, a by-product of industry, makes the method cost-effective and reduces the environmental burden. The main results of the study showed that carbonate sludge has a high sorption capacity for petroleum products. The adsorption isotherm belongs to type I according to the Brunauer, Deming, Deming and Teller classification, which indicates the presence of monolayer adsorption on the sludge surface. It was found that the sludge is able to remove up to 95% of pollutants from wastewater. The value of the study lies in demonstrating that carbonate sludge is an effective and affordable material for solving environmental problems associated with water pollution by petroleum products. This research contributes to the development of industrial waste recycling technologies by offering a newapplication for carbonate sludge. The practical significance of this work lies in the possibility of introducing this method at industrial enterprises for wastewater treatment, which can lead to a reduction in waste disposal costs and an improvement in the environmental situation. The results of the study can be useful for enterprises of the petrochemical industry and wastewater treatment plants.

Research on the corrosion mechanism of Q345R steel under water-oil two-phase flow with the HCl and NH4Cl corrosive medium in low-temperature system of petrochemical plants

The serious corrosion failure phenomenon of HCl and NH4Cl in the water-oil two-phase flow are usually occurred in the low-temperature system of petroleum refinery facilities. In this paper, the corrosion mechanism of these corrosive medium in two-phase flow environment was investigated in detail by using corrosion weight loss, electrochemical measurement methods, surface analysis techniques, and numerical research methods. The results indicate that the corrosion rate of Q345R steel in an HCl-NH4Cl coupling medium falls between the rates observed with each medium alone. The stirring of the corrosive fluid creates an unstable oil-in-water emulsion. The formation of an oil film on the surface of Q345R steel slows down the corrosion process and alters the surface corrosion morphology when the oil phase was not originally present. Increasing the proportion of the water phase accelerates the corrosion rate, and the stronger wettability of the oil phase makes the loose γ-FeOOH products easier to cover the surface, which can effectively prevent the mass transfer and corrosion reaction process.

Experimental and numerical study on explosion resistance of polyurea-coated shelter in petrochemical industry

To reduce the number of casualties in explosion accidents, blast-resistant shelters can be used to protect personnel in high-risk areas of petrochemical processing plants. In this work, the deformation behaviours of uncoated and polyurea-coated blast-resistant plates were studied through gas explosion tests. An ANSYS/LS-DYNA model of a polyurea-coated shelter was established, and the dynamic responses of the shelter under various explosion loads were analysed. A series of fuel–air explosion tests were carried out to investigate the explosion resistance of the full-scale shelter. The results showed that compared with the uncoated blast-resistant plate, the deformation of the polyurea-coated blast-resistant plate was significantly reduced. The overall deformation of the shelter was the central depression of the wall and the inward bending of the frame. The damage effect of a typical high-overpressure, low-duration load was greater than that of typical low-overpressure, long-duration load. The shelter remained intact under three repeated explosive loads, with cracks appearing on the inner wall but no collapse or debris splashing. The shock wave attenuation rate of the shelter reached over 90%, which could significantly reduce the number of indoor casualties.

Elevated airborne radioactivity downwind of a colorado oil refinery

ABSTRACT Airborne radioactivity from fossil fuel production systems is poorly characterized, but a recent study showed elevated ambient levels with proximity to oil and gas production wells. Here, we report year-long, high temporal resolution monitoring results of airborne alpha radioactivity from both radon gas and radon progeny attached to particulates immediately northeast of an oil refinery in Commerce City, Colorado, USA, in an environmental justice community of concern. Gas and particle-associated radioactivity contributed nearly evenly to the total alpha radioactivity. Total radioactivity levels of 30–40 Bq m−3 were 2–3 times higher than background levels (~10–15 Bq m−3) when winds were light and southwesterly, suggesting the refinery as the geographic origin. Furthermore, elevated airborne radioactivity tracked most closely with the light hydrocarbon and natural gas tracer ethane. Thus, the data imply natural gas as the radon emission carrier, possibly from flaring. However, this could not explain all our particle-associated radioactivity observations. Our findings are unique and suggest a need for further investigations of radon emissions from oil and gas infrastructure such as natural gas processing plants, compressor stations, petrochemical plants, and oil refineries that process oil and natural gas from unconventional production. Implications Statement: Regulatory agencies currently do not mandate or conduct monitoring of radioactivity releases and public exposure from petroleum industry air emissions. This study reports elevated radioactivity from radon gas and nonvolatile radon decay products attached to particulate matter, at about 2-3 times above background levels in proximity to Colorado’s largest oil refinery. Observations were within an environmental justice community of concern that experiences well above-average exposure to many other harmful atmospheric pollutants, suggesting potential adverse health effects from this cumulative exposure. Our findings offer actionable insights for policymakers, industry stakeholders, and affected communities alike.